Embossed pile fabric



March l5, 1932. E. T. PHoEN|x EMBOSSED PILE FABRIC Filed March 24, 1931INV ENTOR ATTORNEY ldatenled Mar. V15, 193% PATENT ortica nanns'r T.suomi canrn'r so,

in.; on AMSTERDAM, Nnw YORK,

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ASSIGNOR TO BIGELOW-SANFORD A CORPORATON OF MASSA pplicaton led Haren24, 1931. Serial No. ta/fifth This invention relates to pile fabricssuch as carpets and rugs wherein the pile effect or surface is producedby pile forming yarn or threads secured to a backing of warp and 5 weftthreads.

In some Oriental floor coverings, such for instance as Chinese rugs, anembossed eect is sometimes produced by slightly trimming the ground pilearea which surrounds the iigig ure or pattern after the 'fabric is wovenand completed. v This trimming operation is perormed by hand and issubject to the inherent imperfections due to manual trimming and in suchloor covering practically all of the is ground pile is of the sameheight as the figure and yet produces an embossed effect.

One of the obiects of the present invention a is to provide a floorcovering such as carpets and rugs and method of making the same with apilesurfaoeformed of a ground pile area and a figure `or pattern pilearea an wherein one orl more or pattern pile area are omitted to-fornr aspace between the ground and ligure or pattern pile area andtherebyproduce in the iigure or pattern pile 'area a contrastingappearance resembling an embossed ellect. -f

The pile forming yarns or threads fare usually arranged in transverserows and are secured to a'backing fabric, and in accordance with thepresent invention each row where the figure or pattern and ground occurhas omitted therefrom one or more pile forming yarns or threads toproduce a space or separation between the ground forming pile and thefigure or pattern forming pile, with the result that during the weavingoperation the contrasting appearance or embossed eiiect is produced freefrom all imperfectionsof v the hand trimming operation as heretoforepracticed to some extent.

' An enhancement of the embossed ede'ct may bel secured in some cases byforming the ground pile and the figure or pattern'pile of different plyyarns, and where the figure pile yis produced by. a larger or'heavierply yarn than the ground pile, the embossed etl'ect becomes pronouncedand emphasized during wear, and especially is this the case Where the ofthe series of pile forming yarns or threads'ad3'acent the iigure y pitchor number of threads per inch re mains constant.

The invention and novel features thereof will best be made clear fromthe following description and accompanying drawings of oneembodimentthereof.

Fig. is a perspective view of a pile fabric containing the presentinvention, the edge of the fabric being shown in longitudinal section;and- Y i Fig. 2 is a cross section.

The fabric shown by the drawings is of the Axminster type wherein thepile forming areas are produced by pile forming yarns secured to abacking fabric, and while the backing fabric shown is illustrative ofone character or construction thereof it is to be vunderstood that thebacking fabric may be of any desired character and comprise any usualcombination of warp or weft threads for binding or supporting the pileforming` As shown in the present embodiment of the invention the backingfabric comprises the weft threads 2 at the back of the fabric,theintermediate weft threads 3 in the cen- Y tral portion of the fabricand the top or surface weft threads 4, but as hereinbefore stated thisis merely illustrative of one character of backing fabric that may beemployed and in the present instance of the invention the series of weftthreads 2, 3 and 4 are arranged in pairs, signifying thereby that theweft threads have been introduced into the shed 'by needle mechanism.

Between the back weft threads 2 and the intermediate weft threads 3, thepresent illustration of the invention shows a stutter 5 and likewisebetween the intermediate weft threads 3 and the surface weft threads 4is another stuiler 6, the weft threads and stuiiers being bound togetherby the warp threads 7. The backing fabric thus described may be of usualconstruction, however.

As shown in the present illustration of the invention the ground formingpile yarns 8 and the figure or pattern forming pile yarns 9 are bound orsecured to the backing .fabric by passing about two of the intermediate'spectively may yar s may weft threads 3, but as hereinbefore indicatedthe pile forming yarns constituting the ground and ligure may be securedto the backing fabric in a variety of ways since such eature does notform an essential element e present invention. he ground pile area l0and the figure pile area ll have a defined separation about the contourof the figure as indicated at.l2, and such separationof the two areas isproduced e contrasting appearance between the ground pile area and thefigure pile area may be emphasized by forming the two pileformintroduced into and secured to the backing fabric in transverse rowsand in order that the space between the ground pile area and the figurepile area l0 and 11 rebe formed to bring out the embossed eifect orappearance one or more of the pile forming yarns of each row where theground and gure come together are omitted.

In the illustrated embodiment of the invention the ground pile area 10is made` of a two ply yarn as indicated in in the figure or pattern pilearea the yarn is of three ply and the setting is arranged so as toleaveout one or more ends of the ground pile area directly adjacent tothe figure pile area to be produced. is may not always i necessary as anembodiment of the invention since the pileforming yarns of both theground and figure may be of the same ply.

he use of a three ply yarn in the figure and a two ply yarn in theground with the saine pitch or number of threads per inch retainedthroughout, and the obvious crowding of the heavier yarns in the figure,has a tendency portion of the pile yarn conreason of the ground p`ilearea being more sensitive to the tread.

s liereinbefore indicated be introduced understood, as for instance, inthe production of an Axminster fabric tube frames may be employed fordelivering the pile yarn material to the warps, or nippers or grippersmay be employed as now well understood for weaving such- Axininsterfabric either face up or face down, or the fabric may be woven on aJacquard loom wherein all the frames are alive with separate grids forlifting the Fig. 2 while th p threads,

fabric and pile forming threads or the pile may be variously produced byany of the mechanisms now well understood in the art, the essentials ofthe invention being that between the figure forming pile yarn and theground forming pile yarn a space be provided b.l erably of the groundadjacent to the periphery of the figure, thereby bringing out andemphasizing the contrasting appearance or embossed effect. Ifv desiredthe fabric may be sheared as usual, and by a subsequent washingoperation the pile areas are softened l cause tl flatten somewhatdirectly adjacent to the outline of the gure whereby a still furthereffect may be produced.

l,"Vliat is claimed is f .As an article of manufacture, a woven apattern pile area an effect of increased contrast.

2 As an article of manufacture, a woven fabric com irisine a backinnr ofinterwoven l e n warp and weft to a figure pile area and a ground tEilearea of different color, one Series at least of the pile forming yarnabout the figure pile area being omitted during weaving to cause aseparation between the figure ile and ground pile to produce a contrastofp ance between the figure pile area and the ground pile area.

yarns and a number about the outline of the fi being omitted duringweaving to produce in the iigure pile area an embossed effect orappearance.

5. As an article of manufacture, a woven fabric having a bacln'ng ofwarp and weft and a pile surface which comprises a ground pile areaformed of. a two ply yarn,

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and a figure pile area formed of a three ply yarn, and one of the seriesof the ground two p15T yarn adjacent the ligure pile area being omittedto produce an embossed elect in the figure pile area.

6. As an article of manufacture, a woven fabric having a backing of warpand weft threads, and a pile surface, comprising, a. ground pile areaand a figure pile area., said two pile areas being formed of differentply yarn and woven with the same pitch, and a number of pile formingyarn adjacent the outline of the figure pile .area being omitted toproduce in the figure pile area. an embossed effect.

7. The method of producing a figured pile fabric having an embossedappearance, which consists in weaving a backing fabric, securingtransverse rows of ground and figure producing pile forming yarn to thebacking fabric and omitting from each of said rows during weaving one ormore of the pile forming yarn about the contour of the figure to form aspace between the ground pile and iigure pile and produce a contrast ofappearance between the figure pile area and the ground pile' area.

' 8. The method of producing a figured pile fabric having anembossedappearance, which consists in Weaving a backing fabric,introducing successive rows of pile forming yarn to the backing fabricfor the production of -the pile ground and pile figure, and omittingfrom each row of pile forming yarn during weaving, a ground forming pileyarn at a point next to the contour of the pile figure to form a spacebetween the ground pile and gure and produce a contrasting appearancebetween the figure pile area and the ground pile area.

9. As an article of manufacture, a woven` pile fabric comprising abacking of warp and weft threads, a ground pile area formed of pile yarnof one color or combination of colors, and a figure pile area formed ofdifferent color or combination of colors, one or more of the series ofpii'e forming yarn about the ligure pile area being omitted duringweaving to form a space about the figure pile area and produce acontrast of appearance between lthe iigure pile area and the ground pilearea.

In testimony whereof, I have signed my 55 name to this specification. e

- ERNEST T. PHOENIX.

